How to Replace the Cord Protector on a DeWALT Polisher

The power cord passes through the cord protector as it goes into the polisher's handle. The cord protector gives extra support to the cord, preventing it from kinking and rubbing against the handle. The cord protector is made of rubber and will eventually harden and crack. Once it does, the cord can tend to kink near the handle. This can lead to broken wires. Left unprotected, the cord can also rub against the handle housings, eventually rubbing through the insulation, leaving bare wires.

Let's get started.

REMOVING THE CORD PROTECTOR   1. Remove the top half of the handle.

a. Remove the screws securing the top half of the handle to the lower half.

b. Lift the top half of the handle away from the lower half.

  2. Remove the cord protector.

a. Remove the two screws securing the cord clamp to the lower handle.

b. Remove the cord clamp.

c. Remove the screw securing the switch to the lower handle.

d. Lift the switch assembly out of the lower handle.

e. Disconnect the two cord wires from the switch. (The wires are secured by 'trap door' connectors. To disengage the connectors, insert a small pick into the openings on the switch and pull the wires out of the switch.)

f. Remove the cord assembly from the unit.

g. Remove the cord protector from the power cord.

INSTALLING THE NEW CORD PROTECTOR

  3. Install the cord protector.

a. Thread the cord wires through the new cord protector.

b. Slide the cord protector onto the insulated portion of the cord (until approximately an inch of insulation is visible in front of the cord protector).

REASSEMBLING THE UNIT

  4. Reinstall the cord and switch.

a. Connect the two cord wires to the switch.

b. Install the switch assembly into the lower handle.

c. Secure the switch with the screw.

d. Align the cord protector with the slot on the lower handle.

e. Install the cord clamp.

f. Secure the cord clamp with the two screws.

  5. Reinstall the top of the handle.

a. Tuck any exposed wires into the lower handle.

b. Install the top half of the handle.

c. Secure the top half of the handle with the screws.